Two-component polyurethane or polyisocyanurate low pressure spray foam composition containing a gaseous blowing agent comprising pressurized carbon dioxide

Abstract

Storage-stable two-component polyurethane or polyisocyanurate spray foam compositions are disclosed, said compositions comprising: (a) an A-side component comprising one or more polyisocyanate and one or more blowing agent; and (b) a B-side component comprising one or more polyol and one or more blowing agent comprising pressurized gaseous carbon dioxide and one or more liquid blowing agent; wherein both the A-side component and the B-side component, separately, generate less than 300 ppm of fluoride ion after one week of aging at 50° C.

What is claimed: 
     
       1. A storage-stable two-component polyurethane or polyisocyanurate spray foam composition comprising:
 a) an A-side component comprising one or more polyisocyanate and one or more blowing agent; and 
 b) a B-side component comprising one or more polyol and one or more blowing agent comprising pressurized gaseous carbon dioxide and one or more liquid blowing agent, and further comprising a catalyst; 
 wherein the A-side component is contained in an A-side component container and the B-side component is contained in a B-side component container; and further 
 wherein both the A-side component and the B-side component, separately, generate less than 300 ppm of fluoride ion after one week of aging at 50° C. 
 
     
     
       2. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 1 , wherein the pressurized gaseous carbon dioxide in the B-side component is present at a level of from 0.5 wt. % to 10 wt. % carbon dioxide, based on the total weight of the B-side component. 
     
     
       3. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 1 , wherein the pressurized gaseous carbon dioxide in the B-side component provides a pressure of from 0.14 MPa to 4.00 MPa (21 psig to 580 psig) on the B-side component as measured at ambient temperature. 
     
     
       4. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 1 , wherein the one or more liquid blowing agent in the B-side component is present at a level of from 10 wt. % to 40 wt. %, based on the total weight of the B-side component. 
     
     
       5. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 1 , wherein the one or more liquid blowing agent in the B-side component is or comprises a hydrohaloolefin. 
     
     
       6. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 5 , wherein the one or more blowing agent in the A-side component is or comprises a hydrohaloolefin gaseous blowing agent. 
     
     
       7. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 1 , wherein the one or more liquid blowing agent in the B-side component is or comprises a hydrofluoroolefin, hydrochloroolefin or a hydrofluorochloroolefin. 
     
     
       8. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 1 , wherein the one or more liquid blowing agent in the B-side component is or comprises (E)-1-chloro-3,3,3-trifluoropropene (HFO-1233zd). 
     
     
       9. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 1 , wherein both the one or more blowing agent in the A-side component and the one or more liquid blowing agent in the B-side component comprise a hydrohaloolefin blowing agent. 
     
     
       10. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 1 , wherein both the A-side component and the B-side component comprise one or more liquid blowing agent. 
     
     
       11. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 1 , wherein both the A-side component and the B-side component comprise one or more blowing agent comprising pressurized gaseous carbon dioxide and one or more liquid blowing agent. 
     
     
       12. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 1 , wherein the catalyst comprises a morpholino compound. 
     
     
       13. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 12 , wherein the morpholino compound is 4-(2-hydroxyethyl)morpholine, dimorpholinodiethyl ether, 4-(2-chloroethyl)morpholine, 4-ethylmorpholine, 4-methylmorpholine or 4-(2-aminoethyl)morpholine, or a combination thereof. 
     
     
       14. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 1 , wherein the B-side component further comprises a flame retardant that is an alkylphosphate, an alkylphosphonate, or combination thereof. 
     
     
       15. The storage-stable two-component polyurethane or polyisocyanurate spray foam composition of  claim 14 , wherein the B-side component comprises one flame retardant that is either the alkylphosphate or the alkylphosphonate. 
     
     
       16. A method of providing a space filling layer or space filling volume adjacent to or on a surface, the method comprising:
 (a) providing a foamable composition comprising:
 (i) an A-side component comprising one or more polyisocyanate and one or more blowing agent; and 
 (ii) a B-side component comprising one or more polyol and one or more blowing agent comprising pressurized gaseous carbon dioxide and one or more liquid blowing agent, and further comprising a catalyst; 
 
 wherein the A-side component is contained in an A-side component container and the B-side component is contained in a B-side component container; 
 wherein both the A-side component and the B-side component, separately, generate less than 300 ppm of fluoride ion after one week of aging at 50° C.; 
 (b) applying a foamed sample, or pre-foamed sample that generates a foamed sample, of the foamable composition to said surface; and 
 (c) allowing the foamed sample of foamable composition to cure to a foam having a density of less than 48 kg/m 3 . 
 
     
     
       17. The method of  claim 16 , wherein the pressurized gaseous carbon dioxide in the B-side component is present at a level of from 0.5 wt. % to 10 wt. % carbon dioxide, based on the total weight of the B-side component. 
     
     
       18. The method of  claim 16 , wherein the pressurized gaseous carbon dioxide in the B-side component provides a pressure of from 0.14 MPa to 4.00 MPa (21 psig to 580 psig) on the B-side component as measured at ambient temperature. 
     
     
       19. The method of  claim 16 , wherein the one or more liquid blowing agent in the B-side component is or comprises a hydrohaloolefin. 
     
     
       20. The method of  claim 16 , wherein the one or more liquid blowing agent in the B-side component is or comprises (E)-1-chloro-3,3,3-trifluoropropene (HFO-1233zd). 
     
     
       21. The method of  claim 16 , wherein the step of applying the foamed sample is performed by spraying the foamable composition. 
     
     
       22. The method of  claim 16 , wherein the catalyst comprises a morpholino compound. 
     
     
       23. The method of  claim 22 , wherein the morpholino compound is 4-(2-hydroxyethyl)morpholine, dimorpholinodiethyl ether, 4-(2-chloroethyl)morpholine, 4-ethylmorpholine, 4-methylmorpholine or 4-(2-aminoethyl)morpholine, or a combination thereof. 
     
     
       24. The method of  claim 16 , wherein the B-side component further comprises a flame retardant that is an alkylphosphate, an alkylphosphonate, or combination thereof. 
     
     
       25. The method of  claim 24 , wherein the B-side component comprises one flame retardant that is either the alkylphosphate or the alkylphosphonate.